Low profile deadbolt assembly

Abstract

A deadbolt assembly includes a bolt housing having a longitudinal sleeve defining a first axis. A bolt is located in the longitudinal sleeve. An elongate member has a first end and a second end portion opposite the first end, the first end being attached to the proximal end of the bolt and the second end portion having a first connector. A rotatable crank has a pivot member, a second connector and an arm. The second connector of the crank is operationally engaged with the first connector of the elongate member. A first actuator assembly has a body, a lock cylinder, and a tailpiece that extends from the lock cylinder and is rotatable around a second axis with respect to the lock cylinder. The tailpiece is engaged with the pivot member of the crank. At least a portion of the lock cylinder extends past a vertical plane of an outer side surface of the elongate member.

1. A deadbolt assembly, comprising:
 a bolt housing having a longitudinal sleeve defining a first axis; 
 a bolt having a distal end and a proximal end, said bolt being located in said longitudinal sleeve and configured to move between a fully retracted position and a fully extended position along said first axis; 
 an elongate member having a first end and a second end portion opposite said first end, said first end being attached to said proximal end of said bolt and said second end portion having a first connector, said elongate member having a first outer side surface and a second outer side surface, said second outer side surface being spaced apart from said first outer side surface; 
 a rotatable crank having a pivot member, a second connector and an arm extending between said pivot member and said second connector, said second connector of said crank being operationally engaged with said first connector of said elongate member; and 
 a first actuator assembly having a body, a lock cylinder and a tailpiece, said lock cylinder being mounted to said body, and said tailpiece extending from said lock cylinder, said tailpiece being rotatable around a second axis with respect to said lock cylinder, and said tailpiece being engaged with said pivot member to facilitate rotation of said crank with a corresponding rotation of said tailpiece around said second axis, and wherein at least a portion of said lock cylinder extends past a vertical plane of said first outer side surface of said elongate member, further comprising a guide rail, said guide rail having a notch wherein said lock cylinder defines a perimetrical surface that is positioned within said notch of said guide rail, with a perimetrical surface of said notch accommodating an extent of said lock cylinder. 
 
   
   
     2. The deadbolt assembly of  claim 1 , wherein said lock cylinder is positioned at one of under and over said elongate member. 
   
   
     3. The deadbolt assembly of  claim 1  wherein when mounted to a door having an interior side, an exterior side, and a bore passing through said door from said exterior side to said interior side, said first actuator assembly is inserted into said bore from said exterior side toward said interior side, said first outer side surface of said elongate member facing toward said exterior side of said door and said second outer side surface facing toward said interior side of said door, wherein said arm of said crank is positioned between said second outer side surface of said elongate member and said interior side of said door. 
   
   
     4. The deadbolt assembly of  claim 1 , further comprising a second actuator assembly including a mounting plate, a turnpiece and said crank, wherein said turnpiece and said crank are rotatably mounted to said mounting plate, said pivot member of said crank being connected to said turnpiece to facilitate rotation of said crank with a corresponding rotation of said turnpiece around said second axis, and wherein said arm of said crank is interposed between said second outer side surface of said elongate member and said mounting plate of said second actuator assembly. 
   
   
     5. The deadbolt assembly of  claim 1 , wherein said guide rail is a stationary guide rail attached to said bolt housing, said stationary guide rail defining a third axis that is substantially parallel to said first axis, and said elongate member being configured for only longitudinal movement along said third axis when said bolt is moved between said fully retracted position and said fully extended position. 
   
   
     6. The deadbolt assembly of  claim 1 , wherein said first end of said elongate member is attached by a pivot member to said bolt, and wherein said second end portion of said elongate member travels in an arcuate path when said bolt is moved between said fully retracted position and said fully extended position via rotation of said crank. 
   
   
     7. The deadbolt assembly of  claim 6 , wherein said elongate member is shaped to define a notch to provide a clearance between a first perimetrical surface of said lock cylinder and a second perimetrical surface of said elongate member to accommodate an extent of said lock cylinder past said elongate member. 
   
   
     8. The deadbolt assembly of  claim 7 , wherein said elongate member has a curved shape. 
   
   
     9. The deadbolt assembly of  claim 1 , wherein one of said first connector and said second connector is an aperture, and the other of said first connector and said second connector is a pin extending in a direction substantially parallel to said second axis to engage said aperture. 
   
   
     10. A deadbolt assembly, comprising:
 a bolt housing having a longitudinal sleeve defining a first axis; 
 a bolt having a distal end and a proximal end, said bolt being located in said longitudinal sleeve and configure to move between a fully retracted position and a fully extended position; 
 a first actuator assembly having a body, a lock cylinder and a drive, said lock cylinder being mounted to said body, and said drive extending from said lock cylinder, said drive being rotatable around a second axis with respect to said lock cylinder; 
 a slide member having a first end and a second end portion opposite said first end, said first end being attached to said proximal end of said bolt and said second end portion having a first connector; 
 a rotatable crank having a pivot member, a second connector and an arm extending between said pivot member and said second connector, said pivot member being engaged with said drive of said first actuator assembly to facilitate rotation of said crank with a corresponding rotation of said drive around said second axis, and said second connector of said crank being operationally engaged with said first connector of said slide member; and 
 a stationary guide rail attached to said bolt housing, said guide rail defining a third axis that is substantially parallel to said first axis, and said slide member being configured for longitudinal movement along said third axis when said bolt is moved between said fully retracted position and said fully extended position, said stationary guide rail having a notch, and said lock cylinder having an upper surface positioned within said notch of said stationary guide rail, with a clearance between said upper surface of said lock cylinder and a lower surface defined by said notch to accommodate an extent of said lock cylinder. 
 
   
   
     11. The deadbolt assembly of  claim 10 , said slide member having a first outer side surface and a second outer side surface, said second outer side surface being spaced apart from said first outer side surface, wherein at least a portion of said lock cylinder extends past a vertical plane of said first outer side surface of said slide member. 
   
   
     12. The deadbolt assembly of  claim 11  wherein when mounted to a door having an interior side, an exterior side, and a bore passing through said door from said exterior side to said interior side, said first actuator assembly is inserted into said bore from said exterior side toward said interior side, said first outer side surface of said slide member facing toward said exterior side of said door and said second outer side surface facing toward said interior side of said door, wherein said arm of said crank is positioned between said second outer side surface of said slide member and said interior side of said door. 
   
   
     13. The deadbolt assembly of  claim 11 , further comprising a second actuator assembly including a mounting plate, a turnpiece and said crank, wherein said turnpiece and said crank are rotatably mounted to said mounting plate, said pivot member of said crank being connected to said turnpiece to facilitate rotation of said crank with a corresponding rotation of said turnpiece around said second axis, and wherein said arm of said crank is interposed between said second outer side surface of said slide member and said mounting plate of said second actuator assembly. 
   
   
     14. The deadbolt assembly of  claim 10 , wherein one of said first connector and said second connector is an aperture, and the other of said first connector and said second connector is a pin extending in a direction substantially parallel to said second axis to engage said aperture. 
   
   
     15. A deadbolt assembly, comprising:
 a bolt housing having a longitudinal sleeve defining a first axis; 
 a bolt having a distal end and a proximal end, said bolt being located in said longitudinal sleeve and configure to move between a fully retracted position and a fully extended position; 
 an elongate member having a first end, a second end portion opposite said first end, a first outer side surface and a second outer side surface spaced apart from said first outer side surface, said first end being attached to said proximal end of said bolt, and said second end portion having a first connector; 
 a guide rail attached to said bolt housing, said elongate member being configured for longitudinal movement relative to said guide rail, said guide rail having a notch; 
 a first actuator assembly having a body, a lock cylinder and a tailpiece, said lock cylinder being mounted to said body, and said tailpiece extending from said lock cylinder, said tailpiece being rotatable with respect to said lock cylinder around a second axis, said lock cylinder having an outer surface that is positioned within said notch of said guide rail; and said notch providing a clearance between a surface of said lock cylinder and a surface of said guide rail to accommodate an extent of said lock cylinder 
 a second actuator assembly including a mounting plate, a turnpiece and a crank, said crank having a pivot member, a second connector and an arm extending between said pivot member and said second connector, said second connector of said crank being operationally engaged with said first connector of said elongate member, 
 said turnpiece and said crank being rotatably mounted to said mounting plate, said pivot member of said crank being connected to said turnpiece and to said tailpiece to facilitate rotation of said crank with a corresponding rotation of said turnpiece and said tailpiece around said second axis, and wherein said arm of said crank is interposed between said second outer side surface of said elongate member and said mounting plate of said second actuator assembly. 
 
   
   
     16. The deadbolt assembly of  claim 15 , said guide rail defining a third axis that is substantially parallel to said first axis, and said elongate member being configured for longitudinal movement along said third axis when said bolt is moved between said fully retracted position and said fully extended position. 
   
   
     17. The deadbolt assembly of  claim 15 , wherein said first end of said elongate member is attached by a pivot member to said bolt, wherein said second end portion travels in an arcuate path when said bolt is moved between said fully retracted position and said fully extended position via rotation of said crank. 
   
   
     18. The deadbolt assembly of  claim 15 , wherein one of said first connector and said second connector is an aperture, and the other of said first connector and said second connector is a pin extending in a direction substantially parallel to said second axis to engage said aperture. 
   
   
     19. The deadbolt assembly of  claim 15 , wherein said elongate member is shaped to define a second notch to provide a clearance between an upper surface of said lock cylinder and a lower surf ace of said elongate member to accommodate an extent of said lock cylinder under said elongate member. 
   
   
     20. The deadbolt assembly of  claim 19 , wherein said elongate member has a curved shape. 
   
   
     21. A method of assembling a deadbolt assembly including a bolt housing having a longitudinal sleeve defining a first axis, a bolt having a distal end and a proximal end, said bolt being located in said longitudinal sleeve and configured to move between a fully retracted position and a fully extended position along said first axis; an elongate member having a first end and a second end portion opposite said first end, said elongate member having a first outer side surface and a second outer side surface, said second outer side surface being spaced apart from said first outer side surface; and a guide rail attached to said bolt housing, said elongate member being configured for longitudinal movement relative to said guide rail, said guide rail having a notch, said method comprising:
 providing a rotatable crank having a pivot member, a second connector and an arm extending between said pivot member and said second connector; 
 operationally engaging said second connector of said crank with said first connector of said elongate member; 
 providing a first actuator assembly having a body, a lock cylinder and a tailpiece, said lock cylinder being mounted to said body, and said tailpiece extending from said lock cylinder, said tailpiece being rotatable around a second axis with respect to said lock cylinder; 
 engaging said tailpiece with said pivot member of said crank to facilitate rotation of said crank with a corresponding rotation of said tailpiece around said second axis; and 
 positioning at least a portion of said lock cylinder to extend past a vertical plane of said first outer side surface of said elongate member, with an outer surface of said lock cylinder being positioned within said notch of said guide rail. 
 
   
   
     22. The method of  claim 21 , said method further comprising:
 positioning at least a portion of said lock cylinder at one of under and over said elongate member. 
 
   
   
     23. The method of  claim 21 , wherein when mounting to a door having an interior side, an exterior side, and a bore passing through said door from said exterior side to said interior side, said first outer side surface of said elongate member facing toward said exterior side of said door and said second outer side surface facing toward said interior side of said door, said method further comprising:
 inserting said first actuator assembly into said bore from said exterior side of said door toward said interior side of said door; 
 providing a second actuator assembly including a mounting plate, a turnpiece and said crank, wherein said turnpiece and said crank are rotatably mounted to said mounting plate; 
 inserting said second actuator assembly into said bore from said interior side of said door toward said exterior side of said door; 
 connecting said pivot member of said crank to said turnpiece to facilitate rotation of said crank with a corresponding rotation of said turnpiece around said second axis; and 
 interposing said arm of said crank between said second outer side surface of said elongate member and said mounting plate of said second actuator assembly. 
 
   
   
     24. A deadbolt assembly, comprising:
 a bolt housing having a longitudinal sleeve defining a first axis; 
 a bolt having a distal end and a proximal end, said bolt being located in said longitudinal sleeve and configured to move between a fully retracted position and a fully extended position along said first axis; 
 an elongate member having a first end and a second end portion opposite said first end, said first end being attached to said proximal end of said bolt and said second end portion having a first connector, said elongate member having a first outer side surface and a second outer side surface, said second outer side surface being spaced apart from said first outer side surface; 
 a guide rail attached to said bolt housing, said elongate member being configured for longitudinal movement relative to said guide rail, said guide rail having a notch; 
 a rotatable crank having a pivot member, a second connector and an arm extending between said pivot member and said second connector, said second connector of said crank being operationally engaged with said first connector of said elongate member; and 
 a first actuator assembly having a body, a lock cylinder and a tailpiece, said lock cylinder being mounted to said body, and said tailpiece extending from said lock cylinder, said tailpiece being rotatable around a second axis with respect to said lock cylinder, and said tailpiece being engaged with said pivot member to facilitate rotation of said crank with a corresponding rotation of said tailpiece around said second axis, and wherein at least a portion of said lock cylinder extends past a vertical plane of said first outer side surface of said elongate member, and 
 wherein said lock cylinder defines an outer surface, said outer surface being positioned within said notch of said guide rail. 
 
   
   
     25. The deadbolt assembly of  claim 24 , wherein said outer surface is an upper surface of said lock cylinder.